KIT-CUSHION 5332998 - Caterpillar

Table 1
TYPICAL SYSTEM VOLTAGE DURING CRANKING AT VARIOUS AMBIENT TEMPERATURES    
Temperature     24 V System     12 V System    
-23 to -7° C (-10 to 20° F)     12 to 16 Volts     6 to 8 Volts    
-7 to 10° C (20 to 50° F)     14 to 18 Volts     7 to 9 Volts    
10 to 27° C (50 to 80° F)     16 to 20 Volts     8 to 10 Volts    
Table 2
MAXIMUM ACCEPTABLE VOLTAGE DROPS DURING CRANKING    
Circuit     24 V System     12 V System    
Negative battery post to negative starting motor terminal     1.4 Volts     0.7 Volts    
Drop across disconnect switch     1.0 Volts     0.5 Volts    
+ battery post to positive solenoid terminal     1.0 Volts     0.5 Volts    
Solenoid terminal "Bat" to solenoid terminal "Mtr"     0.8 Volts     0.4 Volts    Test Step 1. CHECK THE BATTERY VOLTAGE
Attempt to crank the engine. Measure the battery voltage with the digital multimeter. Measure the voltage at the battery posts. Do not measure the voltage at the terminal of the battery cable.
Compare the voltage to table 2.Expected Result:The battery voltage is equal to or greater than the voltage in table 2.Results:
OK - Battery voltage is correct. Go to test step 2.
NOT OK - Battery voltage is too low.Repair: Check the charging system. See Special Instruction, REHS 0354, "Charging System Troubleshooting". Stop.Test Step 2. TEST THE DISCONNECT SWITCH
Ensure that the disconnect switch is in the CLOSED position.
Measure the resistance across the terminals of the disconnect switch.Expected Result:The resistance should be less than 5 ohms.Results:
OK - The resistance is less than 5 ohms. The disconnect switch is correct. Proceed to test step 3.
NOT OK - The resistance is greater than 5 ohms. The disconnect switch is not correct.Repair: Replace the battery disconnect switch. Stop.Test Step 3. TEST CABLES FROM THE BATTERY TO THE STARTING MOTOR
Visually inspect the battery cable terminals for the following conditions:
Loose connections
Corroded cablesExpected Result:The cables should be clean and the cables should be tight.Results:
OK - Battery cables are in good condition. Proceed to test step 4.
NOT OK - Battery cables are incorrect.Repair: Clean the terminals or replace the terminals. Tighten the terminals. Stop.Test Step 4. TEST CABLES FROM THE BATTERY TO THE STARTING MOTOR FOR VOLTAGE DROP
Attempt to crank the engine. Measure the voltage from "Mtr" terminal to ground.Expected Result:The battery voltage is less than the voltage in table 2.Results:
OK - The voltage drop is less than the specified voltage drop. Proceed to test step 5.
NOT OK - The voltage drop is greater than the specified voltage drop.Repair: Repair the cables or replace the cables. Repeat the voltage measurement. If the voltage remains low, measure the voltage drop across each component that is listed in table 2. Replace all components that are out of specification. Stop.Test Step 5. CHECK ENGINE ROTATION
Remove the starter from the engine.
Turn the engine by hand.Expected Result: